JP2021165115A - Vehicular cushion pad and manufacturing method thereof - Google Patents

Abstract

To provide a vehicular cushion pad that can prevent any troubles as a product even if gas is left in a longitudinal groove to create a void, stabilize the quality of the product, and improve yields, and to provide a manufacturing method of the vehicular cushion pad.SOLUTION: A vehicular cushion pad 1 in which a second foamed molded product 3 which is a surface layer covers and is laminated on an underlying block-like first foamed molded product 2, includes: a plurality of longitudinal grooves 23 in the vertical direction in a side circumferential direction of a side face 22 of the first foamed molded product 2; and a tape-like object 4 that closes all or a part of respective groove openings 230 of the plurality of longitudinal grooves 23 and is bonded to the side face 22 of the side of the groove openings 230. The second foamed molded product 3 covers the tape-like object 4, and is laminated on the side face 22 of the first foamed molded product 2.SELECTED DRAWING: Figure 1

Description

The present invention relates to a vehicle cushion pad constituting a seat portion of a vehicle seat and a method for manufacturing the same.

Cushion pads that make up the seats of automobiles and other vehicles have been made of flexible polyurethane foam moldings to provide comfortable cushioning, but in recent years, some of them have beads to improve fuel efficiency. There is a growing movement to reduce the weight by replacing the first foam molded body made of a hard foam such as a foam molded body.
The production is carried out using a foam molding mold 7 having a cushion pad cavity C that is closed and upside down from the vehicle installation state (FIG. 15). After setting the first foamed molded product 2 in the upper mold 9, the foaming raw material g is injected into the lower mold 8, but it becomes difficult to release excess gas generated in the foam molding of the flexible polyurethane foam molded product from the mold. There is. This is because the first foamed molded product 2 occupies the upper side of the cavity when the mold is closed, and the product has a structure in which a lack of meat is likely to occur. Therefore, some inventions for measures against lack of meat have been proposed (for example, Patent Documents 1 and 2).

JP-A-2017-206077 Japanese Unexamined Patent Publication No. 2019-187712

In Patent Documents 1 and 2, a through hole penetrating the upper surface side is provided on the lower surface side of the first foamed molded product, and a recess is provided on the upper surface and a through hole is provided in the concave bottom region thereof to provide a surplus gas. Discharges the excess gas out of the mold so that it can easily move toward the through hole.

However, in the foam molding process, it is difficult to collect excess gas generated in the upper surface peripheral area of the first foam molded body in the through hole, and it is structurally possible to provide a dent on the upper surface side even in the upper surface peripheral area. There are difficult cases.
For this reason, the present inventor does not collect the excess gas generated in the upper surface peripheral region of the first foamed molded product into the through hole provided in the upper surface central region of the first foamed molded product, but at least in the peripheral region of the upper surface. It was examined to use a vertical groove provided on the side surface of the first foamed molded product for excess gas. Using the flutes, excess gas rises in the cavity, and studies have been carried out to release the surplus gas from the mold mating surface to the outside of the mold. The beaded foamed molded product of the first foamed molded product and the polyurethane foamed molded product have poor adhesiveness, but since a part of the polyurethane foamed molded product is molded into the flutes, it is also useful for preventing lateral slippage and is suitable ( JP-A-2017-202076).
However, when the vertical groove 23 is provided on the side wall, a void VD may be generated in the vertical groove 23 as shown in FIG. Recently, in order to reduce the weight, the thickness of the lateral surface layer portion of the flexible polyurethane second foam molded body 3 is greatly affected by the fact that the thickness is reduced toward the back surface side of the cushion pad. In the foam molding process, as shown by the arrow in FIG. As shown in the figure (b), a void VD is formed in the vertical groove 23. When the surface of the lateral surface layer portion 32 was pushed from the outside, only the portion where the void VD was present was easily dented and was regarded as a defective product, resulting in a decrease in yield. Furthermore, since the void VD is inside, it is difficult to see visually.

The present invention solves the above-mentioned problems, and even if gas remains in the flutes and voids are formed, the product is not hindered, the quality of the product is stabilized, and the yield is improved. It is an object of the present invention to provide the manufacturing method.

In order to achieve the above object, the gist of the invention according to claim 1 is to provide a cushion pad for a vehicle, which is laminated on a block-shaped first foam molded body as a lower layer by covering it with a second foam molded body as a surface layer. A plurality of vertical grooves formed in the lateral circumferential direction of the side surface of the first foam molded body and all or a part of each groove mouth related to the plurality of formed vertical grooves are closed, and the side surface on the side of the groove mouth. A cushion for a vehicle, comprising a tape-like material attached to the above-mentioned material, wherein the second foam-molded product covers the tape-like material and is laminated on a side surface of the first foam-molded product. It's on the pad. In the vehicle cushion pad according to the second aspect of the present invention, in the first aspect, the tape-like material closes the lower surface side region of the first foam molded product among the groove openings related to the vertical grooves appearing on the side surface. It is characterized in that it is attached to the side surface on the side of the groove mouth. The vehicle cushion pad according to claim 3, wherein one of the tape-shaped objects closes the lower surface side region of the first foam molded product in each groove mouth, and the tape-shaped object and the gap are provided. The region above the lower surface side region of the first foamed molded product is covered with another tape-like material and is attached to the side surface of each groove mouth. The vehicle cushion pad according to claim 4, wherein the tape-like material is a porous tape piece with an adhesive to which an adhesive is applied to the side facing the first foam molded body according to claims 1 to 3. It is characterized by being. The vehicle cushion pad according to claim 5, wherein the porous tape piece is a non-woven fabric piece according to claim 4. The vehicle cushion pad according to claim 6, wherein the tape-like material closes the adhesive and the adhesive applied to the side surface of the groove and covers the groove. It is characterized by comprising a piece of tape attached to the side surface of the groove mouth side. The vehicle cushion pad according to claim 7, wherein the vertical groove reaches the lower end of the side surface from the side surface point below the first foam molded body by removing the upper end portion of the side surface of the first foam molded product. It is characterized in that it is formed up to.
The gist of the invention according to claim 8 is that the lower surface side of the block-shaped first foam molded product is placed on the upper cavity surface of the foam molding mold to set the first foam molded product, and then the first foam molded product is placed on the lower cavity surface. In a method for manufacturing a vehicle cushion pad, in which a foamed raw material is injected and the mold is closed, and then a second foamed molded product on the surface layer is foam-molded by covering and laminating the first foamed molded product so that its lower surface is exposed. Using the first foam molded product in which a plurality of vertical grooves are formed in the lateral circumferential direction of the side surface, all or a part of each groove mouth related to the plurality of vertical grooves is closed with a tape-like material, and the side of the groove mouth is covered. After the tape-shaped material is attached to the side surface of the above and the first foam-molded product is set in the foam-molded mold, the tape-shaped material is covered and laminated on the side surface of the first foam-molded product. (Ii) A method for manufacturing a vehicle cushion pad, which comprises foam molding a foam molded product. The method for manufacturing a cushion pad for a vehicle according to a ninth aspect of the present invention is the method of claim 8, wherein the tape-like material forms a lower surface side region of the first foamed molded product among the groove openings related to the vertical groove appearing on the side surface. It is characterized in that it is closed and attached to the side surface on the side of each groove. The method for manufacturing a cushion pad for a vehicle according to claim 10, according to claim 8 or 9, is that the tape-like material is porous with an adhesive to which an adhesive is applied to the side facing the first foam molded body. It is characterized by being a piece of tape.

The vehicle cushion pad of the present invention and the method for manufacturing the same can prevent defects due to voids even if voids are generated in the flutes of the second foam molded product, and are excellent in maintaining product quality and improving yield. It exerts its effect.

It is a perspective view of the cushion pad in one form of the cushion pad of this invention and the manufacturing method thereof. It is an exploded perspective view of the first foam molded article and a tape-shaped article. It is a perspective view of the first foam molded article with a tape-like material. It is a perspective view of the first foam molded article with a tape-like material of another aspect alternative to FIG. It is a perspective view of the first foam molded article with a tape-like material of another aspect alternative to FIG. It is a partial cross-sectional view which covers the skin on the cushion pad of FIG. FIG. 6 is a partial cross-sectional view of the cushion pad before covering with the skin. It is explanatory cross-sectional view which sets the 1st foam molded article with a tape-like material in an upper mold, and injects a foaming raw material. It is explanatory cross-sectional view which the mold is closed and foam molding proceeds. FIG. 9 is a partially enlarged cross-sectional view of FIG. It is sectional drawing which finished foam molding of the 2nd foam molding body. It is another aspect diagram which replaces FIG. It is another aspect diagram which replaces FIG. It is explanatory drawing sectional drawing in comparison with FIG. It is explanatory sectional view of the prior art.

Hereinafter, the vehicle cushion pad (hereinafter, also simply referred to as “cushion pad”) and the manufacturing method thereof according to the present invention will be described in detail. 1 to 14 are one form of the cushion pad of the present invention and a method for manufacturing the same. FIG. 1 is a perspective view of the cushion pad, and FIG. 2 is an exploded perspective view of the first foamed molded product of FIG. FIG. 3 is a perspective view of the first foamed molded product with a tape-like material, FIG. 4 is a perspective view of the first foamed molded product with a tape-shaped material of another aspect, and FIG. 5 is a first foamed molded product with a tape-shaped material of another aspect. FIG. 6 is a cross-sectional view of the cushion pad of FIG. 1 covering the skin, FIG. 7 is a cross-sectional view of the cushion pad, and FIG. 9A and 9B are explanatory sectional views in which the mold is closed and foam molding proceeds, FIG. 10 is a partial sectional view of FIG. 9, FIG. 11 is a sectional view after foam molding of the second foamed molded product, and FIG. 12 is shown in FIG. Another aspect diagram instead, FIG. 13 shows another aspect diagram instead of FIG. 2, and FIG. 14 shows a cross-sectional view for explaining comparison with FIG. In addition, in order to make each figure easy to understand, the main part of the invention is highlighted for simplification.

(1) Cushion Pad for Vehicle The cushion pad 1 for a vehicle is a seat pad for an automobile or the like that supports and supports the lower body of a seated occupant. This embodiment is applied to the cushion pad 1 as shown in FIG. 1 of the rear seat. If the cushion pad 1 is covered with the skin 5 to form a seat cushion, the known back pad is covered with the skin 5 to form a rear seat with an auxiliary seat added to the center in the vehicle width direction. ..
The cushion pad 1 includes a first foam molded body 2, a vertical groove 23, a tape-shaped material 4, and a second foam molded body 3. In FIG. 1, the diagonally lower left direction of the paper is the front of the vehicle.

The first foam molded product 2 is a foam molded product of a hard foam having a size as shown in FIG. 2 and occupying the lower half of the cushion pad 1 and molded into a block shape. It is a foam molded product such as bead method foamed polypropylene or bead method foamed styrol. For example, in the case of a molded product of bead-method expanded polypropylene (the present embodiment), a highly expanded layer has an arbitrary magnification inside, and the surface becomes a cured film layer. In the non-breathable foam molded product having a surface film, the apparent density after foaming is smaller than that of the second foamed molded product 3, and the first foamed molded product 2 is very light for its size.
The massive first foam molded body 2 is arranged on the lower surface side of the cushion pad 1 in order to reduce the weight of the vehicle, and the lower surface 2b is exposed to become a lower layer of the cushion pad 1. In the present invention, the "lower surface" refers to the "lower surface" of the cushion pad 1 of FIG. 1 mounted on the vehicle and hidden behind the paper surface, and the "upper surface" is the upper side where the buttocks of the seated occupant hit. Refers to the face. The same applies to the “downward” of the seat pad of the present invention, and in the cushion pad 1 of FIG. ..

The vertical groove 23 is a plurality of concave grooves having a U-shaped cross section formed on the side surface 22 of the first foam molded body 2. In the foam molding of the first foam molded body 2, a plurality of vertical grooves 23 running in the vertical direction at predetermined intervals in the circumferential direction of the side surface 22 are molded together. Here, three vertical grooves 23 are provided so as to expose the groove openings 230 on the vehicle front side surfaces 22 of the window-side seat portions 11 excluding the auxiliary seat portions and to penetrate from the upper surface 2a to the lower surface 2b of the first foam molded body 2. ing. An opening at the upper end of the vertical groove 233 appears on the upper surface 2a of the first foamed molded product, and an opening at the lower end of the vertical groove appears on the lower surface 2b (FIG. 2). The actual vertical groove 23 is provided in a larger number than this, and the groove depth dimension is set larger than the groove width of the vertical groove 23. The upper surface 2a around the opening of the upper end 233 of the vertical groove is slightly inclined toward the opening. In the foam molding of the second foam molded body 3 described later, excess foam gas easily flows in.
By the way, in the normal cushion pad 1, the thickness t1 of the second foamed molded body 3 becomes smaller near the lower surface 2b of the first foamed molded body 2, but the thickness t1 of the second foamed molded body 3 becomes smaller near the upper surface 2a of the first foamed molded body 2. The thickness t2 of the difoam molded body 3 is sufficiently secured (FIG. 7). Therefore, at the side surface portion near the upper surface a, the excess foam gas accompanying the foam molding of the second foam molded body 3 can smoothly pass through. In such a case, as shown in FIG. 12, the upper end portion 222a of the side surface 22 of the first foamed molded product 2 is not provided with the vertical groove 23, the upper end portion 222a is removed, and the lower end portion 2221 of the side surface is removed from a point on the lower side surface. It can be a vertical groove 23 until it reaches.
A groove 230 is exposed at a vertical groove 23 on the side surface 22 of the first foam molded body 2, and the groove 230 is closed by the tape-like material 4.

The tape-like material 4 closes all or a part of each groove opening 230 related to the plurality of formed vertical grooves 23, and is attached to the side surface 22 of the first foam molded body beside the groove opening 230 with an adhesive 42. It is a strip-shaped sheet piece 41 with an adhesive 42 (FIGS. 2 and 3). The adhesive 42 in the present invention contains an adhesive.
Specifically, it is a tape-shaped object 4 including an adhesive 42 that can be adhered to the side surface 22 of the first foamed molded product, and a strip-shaped sheet piece 41 to which the adhesive 42 is applied. It is more preferable that the tape-shaped material 4 has the adhesive 42 only at the portion facing the side surface 22, and the portion that directly closes the groove 230 is the strip-shaped sheet piece 41 without the adhesive 42. This is because the foam molding of the second foam molded body 3 enables smooth passage of the strip-shaped sheet piece 41 by the foaming raw material g and the excess foaming gas.

The tape-shaped material 4 may be one in which the strip-shaped sheet piece 41 and the adhesive 42 are separated as shown in FIG. 13 and both are finally integrally attached to the side surface 22. That is, the tape-like object 4 is composed of an adhesive 42 applied to the side surface 22 on the side of the groove 230, a band-shaped sheet piece 41 that covers the adhesive 42 and is attached by closing the groove 230. In the present embodiment, it is not a separate body, but a tape-shaped object 4 in which the adhesive 42 is applied to the strip-shaped sheet piece 41 on the side facing the first foam molded body 2. A tape-shaped object 4 in which one side of the double-sided tape is adhered to the strip-shaped sheet piece 41 may be used. When the strip-shaped sheet piece 41 is a porous tape piece 41a, it is also useful for integrating the first foam molded body 2 and the second foam molded body 3. The foamed raw material g infiltrates into the porous tape piece 41a of the tape-shaped material 4 attached to the first foamed molded product 2 by the foam molding of the second foamed molded product 3, and the foamed raw material g penetrates into the porous tape piece 41a and is passed through the tape-shaped material 4. This is because the second foam molded body 3 can be integrated with the one foam molded body 2.

Here, the adhesive 42 applied to the surface of the strip-shaped sheet piece 41 facing the side surface 22 of the first foamed molded product is the first foamed molded product 2 because the first foamed molded product 2 is made of expanded polypropylene having a small polarity. Difficult to adhere to. Nevertheless, it is possible to use an adhesive for a difficult-to-adhere material and a primer together, and in the present invention, the tape-like material 4 is attached to the first foamed molded product 2 until the foam molding of the second foamed molded product 3 is completed. If it is satisfied. For example, a polyamide-based hot-melt adhesive or a two-component mixed acrylic-based coating type can be used as the present adhesive 42.

On the other hand, the strip-shaped sheet piece 41 of the tape-like material 4 is preferably a porous tape piece 41a as described above. There is a piece of porous tape.
The tape-like material 4 of the porous tape piece 41a having the adhesive 42 on the side facing the first foam molded body 2 covers the groove mouth 230, and the adhesive is applied to the side surface 22 of the first foam molded body on the side thereof. It is adhesively fixed at 42 (FIGS. 2 and 3). In addition, the foamed raw material g penetrates into the porous tape piece 41a and is hardened by the foam molding of the second foam molded body 3, so that the first foamed molded body 2 made of expanded polypropylene and the second foamed molded body made of flexible polyurethane, which are originally difficult to bond, are formed. There is also an effect that the foamed molded product 3 can be bonded to the foam molded product 3 via the tape-shaped material 4. Here, a non-woven fabric tape piece is used as the porous tape piece 41a. The foamed raw material g penetrates into the three-dimensional network structure of the non-woven fabric tape piece and is cured to strengthen the integration between the second foamed molded product 3 and the porous tape piece 41a.

In the cushion pad 1 of the present embodiment, among the groove openings 230 related to the vertical groove 23 appearing on the side surface 22, the tape-shaped material 4 as shown in FIGS. 1 and 6 is the lower surface side region 221 of the first foam molded body side surface 22. Is closed and attached to the side surface 22 of the first foam molded body 2 beside each groove 230. The entire region of the first foamed molded product side surface 22 having the vertical groove 23 may be closed with the tape-like material 4 as shown in FIG. 5, but the region of the first foamed molded product side surface 22 having the vertical groove 23 is located. Of these, even if the tape-shaped object 4 simply closes the lower half of the lower surface 2b side, the problem of the present invention can be solved.
The void VD generated in the vertical groove 23 by foam molding of the second foam molded body 3 is a side surface 22 close to the lower surface 2b of the second foam, and is in the vertical groove 23 as shown in FIG. 15 (b) on the lower surface 2b side. Easy to form in the lower half area. Although it is not visible from the outside, it easily dents when an external force is applied in the direction of the white arrow as shown in FIG.
Therefore, on the side surface 22 of the first foamed molded product, the tape-like material 4 is attached to the lower half region on the lower surface 2b side so as to cover the groove 230 of the vertical groove 23 as shown in FIG. Specifically, both ends of the tape-like object 4 that closes the groove 230 are attached to both side surfaces 22 on the side of the groove 230. Then, even if an external force is applied in the direction of the white arrow in FIG. 7, the tape-like object 4 receives the external force in the same way as the side surface 22 of the other part receives the external force, so that the problem of being easily dented is solved. do.

Further, the tape-like material 4 closes the lower half portion on the lower surface 2b side with the first foam molded body side surface 22 having the vertical groove 23, so that the lower edge of the cushion pad 1 is aligned in the circumferential direction and the appearance is good. Become. The surface 3a of the cushion pad 1 is covered with the skin body 51 as shown in FIG. 14 (a), and the locking tool 52 attached to the terminal of the skin 5 is provided along the peripheral edge of the back surface of the cushion pad. By inserting and locking the concave groove 29 of the molded body 2, it becomes a seat pad. When the locking tool 52 is locked in the concave groove 29, the soft second foam molded body 3 near the lower end of the hard first foam molded body 2 is covered with the cushion pad 1 so that the skin body 51 is stretched without slack. When the skin 5 is stretched, it is compressed as shown in FIG. 14 (a), and the corner portion 321 is slightly crushed and rounded.
On the other hand, in the place where the vertical groove 23 is provided, the soft second foam molded body 3 is filled with the soft second foam molded body 3 from the side surface 22 of the first foam molded body to the groove bottom 231 of the vertical groove 23. When the skin 5 covers the corner portion 322 of the second foamed molded product 3 near the lower end 2211 where the vertical groove 23 of the hard first foamed molded product 2 is located, the corner portion 322 greatly drops from the broken line position as shown in FIG. 14 (b). When the seat pad is formed, the lower edge portion of the seat pad is in the circumferential direction, and the skin 5 covered with the portion 322 where the vertical groove 23 is present and the portion 321 where the vertical groove 23 is not present is uneven, resulting in poor appearance.
However, if the tape-like material 4 closes the side surface 22 on the lower surface 2b side including the lower edge portion of the first foam molded body 2 in each groove mouth 230, such a problem does not occur. Even if the second foamed molded product 3 is filled up to the groove bottom 231 as shown in FIG. 6, the tape-like material 4 covers and blocks the vertical groove 23, and the vertical portion of the second foamed molded product 3 in the vertical groove 23. The dip into the groove filling portion 33 can be prevented. Even if the skin 5 is stretched, as shown in FIG. 6, the corners 322 are slightly crushed and rounded, which is equivalent to that of FIG. 14 (a) without the vertical groove 23, and is applied to the lower edge of the seat pad. The unevenness that was wavy in the circumferential direction disappears.

Further, as shown in FIG. 4, among the groove openings 230, the tape-shaped object 4 not only closes the side surface 22 on the lower surface 2b side of the first foamed molded product, but also the groove openings 230 via the tape-shaped object 4 and the gap ε. Of these, a cushion pad 1 in which the region 222 above the lower surface side region 221 of the first foam molded product side surface 22 is covered with another tape-like material 4 and is attached to the side surface 22 is more preferable. It is more preferable if the side surface 22 of the upper region 222 including the upper end side surface 2221 is closed by another tape-like object 4 (FIG. 4). At the corners of the upper surface 2a of the first foam molded body and the upper end 2221 of the side surface on the front side of the vehicle, the upper surface layer portion 31 of the second foam molded body 3 is laminated, but the seated occupant still hits the back side of the knee. If there is a dent at the upper end of the vertical groove 233, it sometimes feels strange. This discomfort is eliminated by the other tape-like material 4 blocking the upper end region of the groove opening 230 forming the dent and attaching both ends to the side surface 22.

The second foamed molded product 3 is a surface layer of the foamed molded product that is laminated so as to cover the first foamed molded product 2 that is the lower layer, and is composed of a flexible polyurethane foam molded product here.
The lower surface 2b of the first foamed molded product 2 is exposed, and the remaining upper surface 2a and side surface 22 of the first foamed molded product 2 are covered with the second foamed molded product 3. The side surface 22 of the first foamed molded product 2 that covers the tape-shaped material 4 is laminated on the side surface layer portion 32 of the second foamed molded product 3. The tape-like material 4 is attached to the preformed first foam molded body 2. Then, the first foam molded body 2 with the tape-shaped material 4 is used as an insert product, the upper surface layer portion 31 is laminated on the upper surface 2a, and the side surface layer portion 32 is foam-molded on the side surface 22 including the tape-shaped material 4. The second foam molded body 3 in which the back surface 3b abuts on the first foam molded body 2 is molded.
At the location of the vertical groove 23, in the foam molding of the second foam molded body 3, the foamed raw material g penetrates into the vertical groove 23 together with the upper surface layer portion 31 and the side surface layer portion 32, and the vertical groove filling portion 33 is formed. It is foam molded. The vertical groove filling portion 33 projects from the side surface layer portion 32 to fill the vertical groove 23 and abuts on the groove bottom 231 and the groove wall 232. Then, at the location of the tape-shaped material 4, the desired cushion pad 1 in which the tape-shaped material 4 is interposed at the boundary between the vertical groove filling portion 33 and the side surface layer portion 32 is formed.
Such a cushion pad 1 is manufactured as follows.

(2) Manufacturing Method of Cushion Pad for Vehicle The cushion pad 1 is manufactured by, for example, the following manufacturing method. Using the foam molding mold 7, the second foam molding 3 of flexible polyurethane, which is the surface layer on the side where the occupant comes into contact, is foam molded, and the first foam molding 2 and the tape-like material 4 are embedded and integrated by the foam molding. Manufactures cushion pads for vehicles. Prior to production, the first foam-molded product 2 described in (1), the tape-shaped product 4, and the foam-molded mold 7 are prepared.

The first foam molded product 2 is a hard foam foam molded product in which a plurality of vertical grooves 23 are formed in the lateral circumferential direction of the side surface 22 thereof. The tape-shaped material 4 is a strip-shaped sheet piece 41 to which the adhesive 42 adheres to one side.

The foam molding mold 7 is a split mold as shown in FIG. 8, and the lower mold 8 and the upper mold 9 are connected to each other by a hinge (not shown) so as to be openable and closable. When the mold is closed as shown in FIG. 9, the lower cavity surface 81, which is entirely dented in a bowl shape to form a contact surface for the seated occupant, and the upper cavity surface, which is aligned with the lower surface 2b of the first foam molded body 2, which is entirely flat. With 91, the cavity C for the cushion pad 1 is made. The cavity C represents the cross-sectional shape of the cushion pad 1 passing through the vertical groove 23 in FIG. 1 in the vehicle front-rear direction. In the foam molding mold 7 of FIGS. 8 to 11, the cushion pad 1 of FIG. 1 is molded upside down.

The cushion pad 1 is manufactured, for example, as follows by using the first foam-molded body 2, the tape-shaped material 4, and the foam-molded mold 7.
First, a first foam molded body 2 having a plurality of vertical grooves 23 formed on the side surface 22 is used, and all or a part of each groove 230 related to the plurality of vertical grooves 23 is closed with a tape-like material 4 to the side of the groove 230. The tape-like material 4 is attached to the side surface 22. Then, the lower surface 2b side of the first foam molded body 2 with the tape-shaped material 4 is applied to the upper mold cavity surface 91 of the foam molding mold 7, and the first foam molded body 2 is set in the upper mold 9 (FIG. 8). .. Alternatively, after the lower surface 2b side of the first foam molded body 2 is applied to the upper mold cavity surface 91 of the foam molding mold 7 and the first foam molded body 2 is set in the upper mold 9, all or a part of each groove opening 230 is used. Is closed with the tape-like material 4, and the tape-like material 4 is attached to the side surface 22 beside the groove mouth 230.
After setting the first foam molded body 2 with the tape-shaped material 4 in which all or part of each groove 230 is closed with the tape-shaped material 4 in the foam molding mold 7, the injection nozzle NL or the like is placed on the lower mold cavity surface 81. Is used to inject a predetermined amount of the foaming raw material g for the second foamed molded product 3.

In the present embodiment, as the tape-like material 4, a porous tape piece 41a with an adhesive 42 to which an adhesive 42 is applied on the side facing the first foam molded body 2 is used. Of the groove openings 230 related to the vertical grooves 23 appearing on the side surface 22 of the first foam molded product, the tape-like material 4 closes and closes each groove opening 230 in the lower surface side region 221 of the side surface 22 of the first foamed molded product. Both ends of the tape piece 41a are attached to the side surfaces 22 beside each groove 230 (FIGS. 3 and 8). After setting the first foam molded product 2 with the tape-shaped material 4 in the foam molding mold 7, the foaming raw material g is injected onto the lower mold cavity surface 81.

Subsequently, the upper mold 9 is operated to close the mold (FIG. 9). By closing the upper mold 9 and the lower mold 8, the cavity C for the cushion pad 1 in which the first foam molded body 2 with the tape-like material 4 is insert-set is formed. In this embodiment, the foaming raw material g is injected and then the mold is closed, but after the mold is closed, the foaming raw material g can be injected.

After closing the mold, the process proceeds to foam molding of the second foam molded body 3. A second foam molded body 3 made of a flexible polyurethane foam molded body having a seated occupant contact surface portion on the design surface side is foam molded. The mold closed state of FIG. 9 is maintained for a predetermined time to form an upper surface layer portion 31 having a contact surface portion, and the tape-shaped material 4 is impregnated and cured with the foamed raw material g, and the back surface 3b side is the side surface of the first foamed molded product 2. The side surface layer portion 32 that comes into contact with the side surface 22 directly or via the tape-like material 4 is foam-molded. Further, a part of the foaming raw material g forming the side surface layer portion 32 enters the vertical groove 23, and the vertical groove filling portion 33 that fills the vertical groove 23 is foam-molded. In this way, the second foamed molded product 3 is formed in which the back surface 3b side of the second foamed molded product 3 is joined to the upper surface 2a and the side surface 22 of the first foamed molded product.

In the foam molding of the second foam molded body 3, the foamed raw material g rises in the cavity C under the mold closure. Most of the air and excess foam gas existing in the cavity C pass through the through hole (not shown) provided in the center of the upper surface 2a of the first foamed molded product to the lower surface 2b side. Further, the excess foaming gas around the upper surface 2a also rises through the vertical groove 23 and is discharged to the outside of the mold through the mold mating surfaces 89 and 99 and the relief groove (not shown).
On the other hand, the liquid foam raw material g foams and rises to fill the cavity C, and foam-molds the second foam-molded body 3 having the upper surface layer portion 31, the side surface layer portion 32, and the vertical groove filling portion 33. At the same time, in this foam molding process, a part of the foaming raw material g penetrates into the porous tape piece 41a of the tape-like material 4. The foamed raw material g that has penetrated into the fine pores in the porous tape piece 41a impregnates and cures the tape-like material 4. After a lapse of a predetermined time, a second foamed molded product having a side surface layer portion 32 that covers the tape-like material 4 and is laminated on the side surface 22 of the first foamed molded product 2 together with the upper surface layer portion 31 and the vertical groove filling portion 33. The desired cushion pad 1 as shown in FIG. 11 obtained by foam-molding 3 can be obtained.

Here, the foamed raw material g tends to rise along the lower cavity side wall 812 rather than rising along the side surface 22 of the first foamed molded product. As shown in FIG. 9, the foaming raw material g reaching the mold matching surfaces 89 and 99 rises rapidly, and the foaming raw material g reaching the upper mold 9 first enters the vertical groove 23 as shown in FIG. 10 and enters the vertical groove 23. It may block the path of excess foam gas that rises. Excess foam gas is left behind in the cavity C, and a void VD as shown in FIG. 7 is formed on the cushion pad 1 after foam molding.
However, even when such a void VD is formed, the present invention closes the groove mouth 230 related to the vertical groove 23 where the void VD is likely to be formed with the tape-like material 4 so as not to be affected by the void VD. The groove mouth 230 is covered, and the tape-like material 4 having both ends attached to the side surface 22 around the groove mouth 230 is covered with the second foam molding body 3 to be foam-molded, thereby solving the problem of void VD. The desired cushion pad 1 is manufactured.

FIG. 12 shows another aspect diagram in place of FIG. A first foam molded product in which a vertical groove 23 is formed so as to reach from a side surface point below the upper end portion 222a to the lower end of the side surface 22 without providing a vertical groove 23 in the upper end portion 222a of the first foam molded body side surface 22. The desired cushion pad 1 is made using 2.
Reference numeral 12 indicates a connection portion with the backrest. Other configurations are the same as (1) Cushion pad, and the explanation is omitted. The same reference numerals as in (1) indicate the same or corresponding parts.

(3) Effect According to the vehicle cushion pad and the manufacturing method thereof configured as described above, a part of the conventional flexible polyurethane foam molded body is replaced with the light first foam molded body 2 of hard foam, so that the weight is reduced. Can be pushed forward. Nevertheless, since the upper surface layer portion 31 and the side surface layer portion 32 of the second foam molded body 3 made of flexible polyurethane cover the first foam molded body 2 to form the surface layer, the appearance is the same as before. An upper surface layer portion 31 having a large thickness t3 is provided under the buttocks of the seated occupant, and comfortable cushioning is also maintained. Further, during the foam molding of the second foam molded body 3, the excess foam gas generated around the upper surface 2a of the first foam molded body can pass through the vertical groove 23 and be discharged to the outside of the mold through the mold mating surfaces 89 and 99.

Then, in the foam molding of the second foam molded body 3, the foamed raw material g passes through the cavity side wall 812 of the lower mold 8 and reaches the mold mating surfaces 89 and 99 first, and the excess foamed gas from the vertical groove 23 is trapped. Even if a void VD occurs, it does not cause a problem due to the void VD.
As in claims 1 and 8, a tape-like material 4 is attached to the side surface 22 of the first foam molded body on the side of the groove 230 by closing all or part of each groove 230 related to the plurality of formed vertical grooves 23. When the second foamed molded product 3 covers the tape-shaped material 4 and is laminated on the side surface 22 of the first foamed molded product, the groove mouth 230 of the vertical groove 23 where void VD is likely to be formed is covered with the tape-shaped material 4. The void VD under the groove 230 does not affect the product quality because it can be sealed in the form of The void VD is likely to be formed at the groove bottom 231 of the vertical groove 23, and if there is a void VD, the tape-shaped object 4 solves the conventional problem (b of FIG. 15) in which the void VD is easily dented by an external force. (Fig. 7). The tape-like material 4 covers the vertical groove groove 230 having the void VD in an stretched state and is attached to both side surfaces 22 on the side of the groove 230, so that the rigidity is substantially the same as that of the side surface 22 around the groove 230. Play a role in keeping. Therefore, even if an external force as shown by the white arrow in FIG. 7 is applied, the tape-like object 4 blocks the external force so as not to be transmitted to the void VD, and the tape-like object 4 can receive the external force. Even if gas remains in the vertical groove 23 and a void VD is formed, the product is not hindered. It leads to stable product quality and improved yield.

As in claims 2 and 9, the tape-like material 4 closes the lower surface side region 221 of the first foam molded body side surface 22 of each groove opening 230 related to the vertical groove 23, and is attached to the side surface 22 thereof. Even if a void VD is formed in the vertical groove 23, the amount of the tape-like material 4 used can be reduced and the quality of the product can be effectively stabilized. The thickness t1 of the side surface layer portion 32 becomes thinner toward the back surface side of the cushion pad 1, and the void VD is likely to be formed in the vertical groove 23 in the region on the lower surface 2b side of the first foamed molded product. The tape-like material 4 can be attached to the vertical groove 23 of the above, and the above effect can be obtained with a smaller amount of the tape-like material 4 used and a smaller burden of attaching the tape-like material 4.
Further, as described above, when the tape-shaped object 4 aligns the lower end thereof with the lower end of the side surface of the first foam molded body 2 and closes the vertical groove 23 of the lower surface side region 221, it surrounds the lower edge portion of the seat pad 1. The unevenness that was wavy in the direction is also eliminated.

As in claim 3, one of the tape-like objects 4 closes the lower surface side region 221 of the first foam molded body side surface 22 of each groove opening 230, and the groove openings 230 pass through the tape-like object 4 and the gap ε. When the area 222 above the lower surface side area 221 of the first foam molded body side surface 22 is closed by another tape-like object 4 and attached to the side surface 22, the seated occupant is vertically compared with other parts. It is possible to prevent the upper end 233 of the groove from being given a sense of discomfort due to the dent that sometimes occurs.
Although the cushionable upper surface layer portion 31 covers the hard first foam molded body 2, a dent at the upper end 233 of the vertical groove of the first foam molded body 2 may be felt through the upper surface layer portion 31 when seated. The problem is solved by closing the groove 230 at this location with another tape-like object 4. Since the groove mouth 230 in the upper end region of the vertical groove 23 is sealed with the tape-like material 4, even if the vertical groove 23 is present, the occupant does not feel uncomfortable.

As in claims 4 and 10, if the tape-like material 4 is a porous tape piece 41a with an adhesive 42 to which an adhesive 42 is applied to a surface facing the first foam molded product 2, the second foam molded product In the foam molding of 3, the foamed raw material g penetrates into the porous tape piece 41a and hardens, so that the first foamed molded product 2 made of expanded polypropylene and the second foamed molded product 3 made of flexible polyurethane, which were difficult to bond, are tape-shaped. Can be combined via object 4.
As in claim 5, if the porous tape piece 41a is a non-woven fabric piece, the foamed raw material g penetrates into the three-dimensional network structure of the non-woven fabric tape piece and is cured. Therefore, the second foamed molded product 3 and the porous tape piece are cured. The integration with 41a can be further strengthened.
As described above, the cushion pad for this vehicle and the method for manufacturing the same are extremely useful because they exhibit the various excellent effects described above.

The present invention is not limited to the one shown in the above embodiment, and can be variously modified within the scope of the present invention according to an object and an application. The shape, size, number, material, etc. of the first foam molded product 2, the second foam molded product 3, the tape-shaped material 4, the foam molding mold 7, etc. can be appropriately selected according to the intended use.

1 Cushion pad 2 First foam molded body 2b lower surface (first foam molded body lower surface)
22 Side surface (side surface of first foam molded product)
221 Bottom side region 23 Second foam molded body 4 Tape-like material 41a Porous tape piece 42 Adhesive 7 Foam molding mold 81 Lower cavity surface 91 Upper cavity surface C Cavity g Foaming material (polyurethane foaming material)

Claims (10)

In a vehicle cushion pad that is laminated on a block-shaped first foam molded body that becomes a lower layer by covering it with a second foam molded body that is a surface layer.
A plurality of vertical grooves formed in the lateral circumferential direction of the side surface of the first foam molded body, and
A tape-like material that closes all or part of each groove mouth related to the plurality of formed vertical grooves and is attached to the side surface on the side of the groove mouth is provided.
A cushion pad for a vehicle, wherein the second foam molded product covers the tape-shaped material and is laminated on a side surface of the first foam molded product. The first aspect of claim 1, wherein the tape-like material closes the lower surface side region of the first foamed molded product among the groove openings related to the vertical grooves appearing on the side surface, and is attached to the side surface on the side of each groove opening. Cushion pad for vehicles. One of the tape-shaped products closes the lower surface side region of the first foamed molded product among the groove openings, and the lower surface of the first foamed molded product of the groove mouths is provided through a gap between the tape-shaped material and the groove mouth. The vehicle cushion pad according to claim 2, wherein the area above the side area is covered with another tape-like material and is attached to the side surface. The vehicle cushion pad according to any one of claims 1 to 3, wherein the tape-like material is a porous tape piece with an adhesive to which an adhesive is applied to the side facing the first foam molded body. .. The vehicle cushion pad according to claim 4, wherein the porous tape piece is a non-woven fabric piece. A claim in which the tape-like material comprises an adhesive applied to the side surface on the side of the groove, and a piece of tape that closes the groove and covers the adhesive and is attached to the side surface on the side of the groove. Item 6. The vehicle cushion pad according to any one of Items 1 to 3. The aspect of any one of claims 1 to 6, wherein the vertical groove is formed from a side surface point below the upper end portion of the side surface of the first foam molded product to reach the lower end of the side surface. Cushion pad for vehicles. The lower surface side of the block-shaped first foamed molded product is placed against the upper mold cavity surface of the foam molding mold to set the first foamed molded product, and then the foamed raw material is injected onto the lower mold cavity surface and the mold is closed, and then the mold is closed. In a method for manufacturing a vehicle cushion pad, which foam-molds a second foam-molded article on the surface layer, which covers and laminates the first foam-molded article so that its lower surface is exposed.
Using the first foam molded product in which a plurality of vertical grooves are formed in the lateral circumferential direction of the side surface, the first foam molded product is used.
All or part of each groove opening related to the plurality of vertical grooves is closed with a tape-like material, the tape-like material is attached to the side surface of the groove mouth, and the first foam molded product is formed into a foam molding mold. A method for manufacturing a cushion pad for a vehicle, which comprises foam-molding the second foam-molded product that is laminated on the side surface of the first foam-molded product by covering the tape-like material after setting. The first aspect of claim 1, wherein the tape-like material closes the lower surface side region of the first foamed molded product among the groove openings related to the vertical grooves appearing on the side surface, and is attached to the side surface on the side of each groove opening. Cushion pad for vehicles. The method for manufacturing a cushion pad for a vehicle according to claim 8 or 9, wherein the tape-like material is a porous tape piece with an adhesive to which an adhesive is applied to the side facing the first foam molded body.

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